Pod toy

ABSTRACT

A pod toy may include a plurality of substantially similar panels each having a wall portion and a roof portion, the plurality of panels having at least one interlocking edge having alternating notches and knuckles configured for engaging adjacent panels, where, when assembled, the interlocking edge of a first panel engages an interlocking edge of a second panel by aligning knuckles of the first panel with knuckles of the second panel, and a connecting pin configured for insertion into and through the knuckles at the interlocking edges.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 61/920,224 entitled Pod Toy, filed on Dec. 23, 2013, the content of which is hereby incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present disclosure relates to a pod for a child such as a fort, hut, enclosure, or other space that can be occupied by a child for play. More particularly, the present disclosure relates to a sustainable design for a pod. Still more particularly, the present disclosure relates to a structurally sturdy design for a pod including a working door, windows, and a roof opening.

BACKGROUND OF THE INVENTION

The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

Creation of forts or other enclosures within a home for children to play in has long since been a way to entertain. More recently, manufacturers have begun creating cardboard play systems in the form of castles, rockets, and the like. The play systems may be white in color and may come with or be sold in conjunction with or marketed with markers, crayons, or other writing or coloring devices. The overall goal of these systems appears to be to sell more markers or crayons while providing the children with a temporary structure to play with. However, the cardboard play systems are weak-walled and very unstable.

BRIEF SUMMARY OF THE INVENTION

The following presents a simplified summary of one or more embodiments of the present disclosure in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments, and is intended to neither identify key or critical elements of all embodiments, nor delineate the scope of any or all embodiments.

In one or more embodiments, a pod toy may include a plurality of substantially similar panels each having a wall portion and a roof portion. The plurality of panels may have at least one interlocking edge with alternating notches and knuckles configured for engaging adjacent panels. When assembled, the interlocking edge of a first panel may engage an interlocking edge of a second panel by aligning knuckles of the first panel with knuckles of the second panel. The toy may also include a connecting pin configured for insertion into and through the knuckles at the interlocking edges. In contrast to cardboard play systems currently being provided, the present pod toy may be structurally stable with a series of stiffened edges and corners making a pod toy that is not only durable but is capable of supporting the weight of a child. As such, the pod toy may function as a but or fort, for example, but may also allow for climbing in, on, and around, without collapse or general degradation of the toy.

While various embodiments are disclosed, still other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the invention. As will be realized, the various embodiments of the present disclosure are capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present disclosure. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying Figures, in which:

FIG. 1 is a front/right side perspective view of a pod toy, according to one or more embodiments.

FIG. 2 is a rear/left side perspective view of the pod toy of FIG. 1, according to one or more embodiments.

FIG. 3 a is back side view of the pod toy of FIG. 1, according to one or more embodiments.

FIG. 3 b is a left side view of the pod toy of FIG. 1, according to one or more embodiments.

FIG. 3 c is a right side view of the pod toy of FIG. 1, according to one or more embodiments.

FIG. 3 d is a front side view of the pod toy of FIG. 1, according to one or more embodiments.

FIG. 4 is a top view of the pod toy of FIG. 1, according to one or more embodiments.

FIG. 5 is a bottom view of a pod toy similar to that of FIG. 1, but with the back and left sides interchanged, according to one or more embodiments.

FIG. 6 is an exploded view of the pod toy of FIG. 5, according to one or more embodiments.

FIG. 7 is an exploded view of the pod toy of FIG. 5 showing the assembly of the rear wall and the left side wall, according to one or more embodiments.

FIG. 8 is a cross-section view of a bottom edge of the walls of the pod toy, according to one or more embodiments.

FIG. 9 is a cross-section view of a gable corner, according to one or more embodiments.

FIG. 10 is a cross-section view of a side-adjoining or vertical corner, according to one or more embodiments.

FIG. 11 is a cross-section view of a ridge, according to one or more embodiments.

FIG. 12 is a cross-section view of a top opening edge, according to one or more embodiments.

FIG. 13A is a cross-section view through the latch-side jamb of the door with the door in the closed position, according to one or more embodiments.

FIG. 13B is a cross-section view through the latch-side jamb of the door with the door in a slightly opened position, according to one or more embodiments.

FIG. 14A is a cross-section view through the hinge-side of the door with the door in the closed position, according to one or more embodiments.

FIG. 14B is a cross-section view through the hinge-side of the door with the door in a slightly opened position, according to one or more embodiments.

FIG. 15 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 16 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 17 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 18 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 19 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 20 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 21 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 22 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 23 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 24 is a perspective view of a pod toy in a partially assembled condition, according to one or more embodiments.

FIG. 25 is a perspective view of ridge of a pod toy, according to one or more embodiments.

FIG. 26 is a perspective view of a pod toy with a door in an open condition, according to one or more embodiments.

FIG. 27 is a perspective internal view of an inside face of a door, according to one or more embodiments.

FIG. 28 is a cross-section view of an alternative corner or joint, according to one or more embodiments.

FIG. 29 is a cross-section view of an alternative corner or joint, according to one or more embodiments.

FIG. 30 is a perspective view of a pod toy, according to one or more embodiments.

FIG. 31 is a perspective view of a pod toy, according to one or more embodiments.

FIG. 32 is a perspective view of a pod toy, according to one or more embodiments.

FIG. 33 is a perspective view of a pod toy, according to one or more embodiments.

FIG. 34 is a cross-section view of an alternative corner of joint, according to one or more embodiments.

FIG. 35 is a cross-section view of an alternative corner or joint, according to one or more embodiments.

FIG. 36 is a cross-section view of an alternative corner or joint, according to one or more embodiments.

FIG. 37 is an underside perspective view of the corner or joint of FIG. 36, according to one or more embodiments.

FIG. 38 is a perspective view of a pod toy, according to one or more embodiments.

FIG. 39 is a perspective view of a pod toy, according to one or more embodiments.

FIG. 40 is a view of a blank foldable to form a wall and a portion of a roof of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 41 is a view of a blank foldable to form a wall and a portion of a roof of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 42 is a view of a blank foldable to form a wall and a portion of a roof of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 43 is a view of a blank foldable to form a wall and a portion of a roof of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 44 is a view of a blank foldable to form a door of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 45 is a view of a blank foldable to form a handle latch of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 46 is a view of a blank foldable to form corner trim of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

FIG. 47 is a view of a blank foldable to form an inside gable patch of a pod toy such as that shown in FIG. 1, according to one or more embodiments.

DETAILED DESCRIPTION

The present application, in some embodiments relates to a sustainably designed fort, hut, climbing device, or pod for use by children to climb in, on, and/or around. In particular, the pod may have a series of walls, some having windows or other openings, and a roof. The pod may have a door for entering and exiting the pod and the roof may include a roof opening allowing children to stand, sit, or crouch within the pod and poke their head out of the opening or even climb into and out of the pod using the opening. The pod may be sized to accommodate younger children such as toddlers and may be structurally sturdy so as to support the weight of a child weighing up to 100 pounds, for example. The pod may be constructed from sustainable materials commonly used for boxes, carrying devices, or other containers and may be easily decorated with markers, paints, or other common drawing or coloring devices.

Referring now to FIG. 1, a pod 100 is shown. As shown, the pod 100 may include a front wall 102, a back wall 104, a left sidewall 106, and a right sidewall 108. The pod 100 may have a roof constructed from portions of each wall that extend upwardly beyond the wall to form a portion of the roof. The pod 100 may include a front/left roof portion 110, a back/right roof portion 112, a right/front portion 114, and a left/back portion 116. The front/left roof portion 110 may extend from the front wall 102 and form a front/left portion 110 of the roof. The back/right roof portion 112 may extend from the back wall 104 and form a back/right portion 112 of the roof. The right/front portion 114 may extend from the right wall 108 and form a right/front portion 114 of the roof. The left/back portion 116 may extend from the left wall 106 and form a left/back portion 116 of the roof. The portion of the roof that is formed from a respective portion of a wall may be evident from the figures where a fold line is present in lieu of an interlocking seam.

Each of the walls of the pod 100 may take a shape defined, in part, by the number of sides of the pod. In the case of a 4-sided pod, the walls may be 5-sided polygons as shown in FIGS. 3 a-3 d. Each wall may include a bottom edge 118, a vertically extending left edge 120, a top/left gable edge 122, a top/right gable edge 124, and a vertically extending right edge 126. (labeled with A, B, C, and D depending on the FIG. in which they appear). The bottom edge 118 may be a free edge having a left end and right end. The left edge 120 may extend vertically from a bottom point at the left end of the free edge 118 to a top point. The left edge 120 may be arranged substantially perpendicular to the free edge 118 and the left edge 120 may be configured for interlocking engagement with a right edge 126 of an adjacent and out of plane wall to form a corner seam. The top/left gable edge 122 may extend from an eave point at the top point of the left edge 120 upwardly along a slope to a peak end. The top/left gable edge 122 may define a gable slope ranging from about 15 degrees to about 60 degrees, or from about 20 degrees to about 45 degrees, or a slope of about 30 degrees from horizontal may be provided. The top/left gable edge 122 may be defined by a fold line between the wall and a hingedly connected roof portion. The top/right gable edge 124 may extend from a peak end at the peak end of the top/left gable edge 122 downwardly along a slope to an eave point. The top/right gable edge 124 may define a gable slope equal and opposite the gable slope of the top/left gable edge. In contrast to the top/left gable edge 122, the top/right gable edge 124 may be configured for interlocking engagement with a roof portion formed from an adjacent panel to form a gable seam. The right edge 126 may extend vertically from a top point at the eave point of the top/right gable edge 124 to a bottom point at the right end of the bottom edge 118. The right edge 126 may be arranged substantially perpendicular to the bottom free edge 118 and the right edge 126 may be configured for interlocking engagement with a left edge 120 of an adjacent and out of plane wall to form a corner seam.

As indicated, each of the wall panels may have substantially the same shape, size, and edge arrangements. Accordingly, each edge may be discussed in more detail. As shown in more detail, in FIG. 8, the bottom edge 118 may be reinforced so as to be relatively rigid and stiff. That is, without engagement by an adjoining out of plane panel, the free bottom edge 118 may have a tendency to be relatively flexible in a direction out of plane of the wall. The free edge 118 may be reinforced as shown in FIG. 8. That is, the free edge 118 may include an inwardly extending flange portion 128, an upward sloping return portion 130, and a securing flap 132. The flange portion 128 and return portion 130 may increase the section modulus of the free edge 118 and, as such, it may be more resistant to bending out of plane of the wall.

The left edge 120 and right edge 126 of each wall panel may include a series of knuckles 134 configured for interlockingly engaging knuckles on an adjacent intersecting edge. The knuckles 134 may also be configured for receiving a connecting pin or shaft 136 such that the several knuckles on adjoining edges may be aligned by inserting the connecting pin or shaft 136 through a series of aligned knuckles 134. As shown in FIG. 3, for example, the left edge of each panel may include a notch 138 near the bottom end extending to approximately the ¼ point of the left edge 120. The notch 138 may be followed by a knuckle 134 extending to approximately the midpoint of the left edge 120. The knuckle 134 may be followed by another notch 138 extending to approximately the ¾ point of the left edge 120 and another knuckle 134 may be extend to the top end of the left edge 120. It is to be appreciated that the lengths of the notches 138 and knuckles 134 may vary and, as shown in FIG. 40, for example, a portion near the top of each of the left and right edges may be free of knuckles 134 or notches 138 and, as such, the ¼ point, midpoint, and ¾ point may be identified apart from this remaining portion. In contrast to the left edge 120, the right edge 126 of each panel may have an opposite pattern such that where a knuckle 134 is present on a left edge 120, for example, a notch 138 is present on the adjoining right edge 126 and vice versa. It is to be appreciated that other approaches may be taken where not all of the panels are the same and one panel has a first pattern along each edge and other panels have a corresponding pattern along each edge. For example a front and back panel may be the same and right and left panels may be different from the front and back panels, but similar to each other.

As shown in FIG. 10, each knuckle 134 may be formed from an inwardly extending flange 140, a perpendicularly extending return 142, an outwardly extending return 144, an attachment flap 146, a chamfer flange 148, and an outwardly extending closure flap 150. The inwardly extending flange 140, perpendicularly extending return 142, and outwardly extending return 144 may be sized to form a channel, bore, or sleeve 152 through the knuckle 134. In some embodiments, as shown, the sleeve 152 may be substantially square in cross-section and may be sized for a snug fit when the connecting pin or shaft 136 is inserted therethrough. For example, the width of the sleeve 152 may be slightly larger, substantially equal to, or slightly smaller than an outer diameter of the connecting pin or shaft 136 such that insertion of the connecting pin or shaft 136 creates a friction fit between the pin 136 and the inside surface of the knuckle 134. It should be appreciated that portions of the cross-section of FIG. 10 may be continuous along the length of the edge to reinforce the knuckles 134. For example, the attachment flap 146, the chamfer flange 148, and the outwardly extending closure flap 150 may be continuous between knuckles 134. This may help maintain the knuckles 134 remain in general alignment when a connecting pin 136 is not in place.

The top left edge 122 of each panel, as mentioned, may be defined by a fold line between the wall and a hingedly connected roof portion. For example, each of FIGS. 40-43 shows an inside surface of a blank for use in forming a wall panel and the fold line 154 for forming the top left edge 122 of each panel is shown. Accordingly, a cross-sectional view through the top left edge 122 of each panel may simply include an upwardly extending portion of the wall and an adjoining sloping roof portion connected thereto by a living hinge type seam.

The top/right edge 124 of each panel may be somewhat similar to the left and right edges in that it may include one or more knuckles 134 for interlockingly engaging an adjoining roof portion. As shown in FIG. 3 a, for example, the top right edge of each panel may begin with a notch 138 extending from the peak to about the ¼ point as it extends downwardly along the top right edge 124. A knuckle 134 may extend from the ¼ point to about the midpoint and another notch 138 may extend from about the midpoint to the ¾ point and yet another knuckle 134 may extend the remaining length of the top/right edge 124 leaving a last portion to extend to the eave without a knuckle 134 or notch 138. It is to be appreciated that the element configured for engagement with the top/right edge 124 is a gable edge of a roof portion of an adjacent panel and that such an edge may have notches 138 and knuckles 134 sized and spaced for interlockingly engaging the top/right edge 124.

As shown in FIG. 9, the knuckles 134 on the top/right edge 124 and the corresponding roof portion may be shaped slightly differently than those on the left 120 and right edges 122 to accommodate the slope of the roof. As shown, the knuckles may include an inwardly and sloping flange portion 156, a parallel extending return portion 158, and an outwardly and sloping return portion 160. The knuckle 134 may also include an attachment flap 162, a chamfer flange 164, and an optional outwardly extending closure flap (not shown). The knuckle 134 for the top/right edge 124 of the panel may, in some embodiments, be parallelogram shaped in cross-section and may have width measured substantially perpendicular to the wall that creates a friction fit with a connecting pin or shaft 136. As with the knuckles 134 on the left 120 and right edges 126, portions of the cross-section in FIG. 9 may be continuous along the edge including the attachment flap 162 and the outwardly and sloping return portion 164. This may help maintain the knuckles 134 in general alignment when a connecting pin 136 is not in place.

Referring now to FIG. 4, a top view of the pod 100 of FIG. 1 is shown. As shown, each of four roof panels 110, 112, 114, 116 may be substantially the same and each may extend from a respective wall at a fold line. Collectively, the four roof panels may form a generally pyramidal shape. As shown, however, the base of the pyramid may be oriented approximately 45 degrees to the orientation of the walls. That is, were the ridges of the roof structure extended downward to the plane defined by the top end of the wall joints and were the ridges extended upward to a top point of the pyramidal shape, the base of the pyramidal roof structure would be oriented approximately 45 degrees from the orientation defined by the walls.

As shown, each roof panel may include an interlocking gable edge 166, a ridge edge 168, a free roof opening edge 170, another ridge edge 172 and a folded gable edge 174. (Only two panels have been labeled for clarity, but each roof panel may have corresponding edges labeled clockwise in each case and beginning with the interlocking gable edge) The interlocking gable edge 166 may extend from an eave point upwardly along the slope of the top/right gable edge 124 of an adjacent wall panel to a peak. The ridge edge 168 may extend inwardly away from the peak and upward toward a roof opening end. The free roof opening edge 170 may extend away from the roof opening end of one ridge edge 168 to another roof opening end of another ridge edge 172. The remaining ridge edge 172 may extend therefrom downwardly along a slope from the roof opening end to a peak of a gable. The remaining folded gable edge 174 may extend downwardly from the peak to an eave where it may end adjacent a eave end of the interlocking gable edge 166.

The interlocking gable edge 166 may be configured for interlockingly engaging the top/right gable edge 124 of a wall panel and, as such, may include alternating notches 138 and knuckles 134 spaced and sized for interlocking with the notches 138 and knuckles 134 on the top/right gable edge 124 of a wall panel and the knuckles 134 may have a cross-sectional shape similar to that shown in FIG. 9.

The ridge edges 168, 172 may be configured for abutting an adjacent ridge edge on an adjacent roof panel. As shown in FIG. 11, each ridge edge 168, 172 may include an inwardly extending flange portion 176, a return portion 178, and a securing flap 180. The inwardly extending flange portion 176 may be configured to abut an adjacent inwardly extending flange portion 176 of an adjacent roof section.

The free roof opening edge 170 may be a stiffened edge similar to the bottom edge 118 of the walls. However, in order to accommodate the slope of the roof, the cross-section may be slightly different. As shown in FIG. 12, the free roof opening edge 170 may include a inwardly extending flange portion 182, a return portion 184, and a securing flap 186. In this case, the inwardly extending flange portion 182 may be configured to be arranged substantially vertically when the pod 100 is assembled and, as such, substantially parallel to the walls of the pod 100.

As discussed with respect to the wall panels, the folded gable edge 174 may be defined by a fold line between a wall panel and an attached roof panel.

As shown in FIG. 6, the pod 100 may be assembled from four substantially similar panels. As shown, with the exception of the openings in the wall portion of a panel, each of the panels may be substantially the same including a wall portion and a roof portion. In some embodiments, one of the roof portions may include a tab or slot for inserting a last connecting pin or shaft 136 along an interlocking gable edge. However, the panels may otherwise be substantially the same.

One of the panels for the pod may include a door 188 as shown in FIG. 3 d. The door 188 may be configured to open and close through pivoting motion about a hinge, for example. The door 188 may include a substantially flat panel having a bottom edge 190, a top edge 192, and two side edges 194, 196. The door 188 may have a reinforced perimeter edge as shown in FIGS. 13-A, 13-B, 14-A, and 14-B. The reinforced perimeter edge may include a doubled over portion 198, a inwardly extending sloping portion 200, an outwardly extending sloping portion 202, and an attachment flap 204. The inwardly extending sloping portion 200 and the outwardly extending sloping portion 202 may form a substantially uniform triangular cross-section extending around the perimeter of the door panel 188 creating a substantially stiff panel. As shown in FIGS. 13-A and 13-B, on the latch side of the door 188, the doubled over portion 198 of the door may be configured to releasingly abut an outer surface of the wall panel on which the door 188 is positioned. As shown in FIGS. 14-A and 14-B, on the hinge side of the door 188, the doubled over portion 198 may be configured for securing the door 188 to an outer surface of the wall panel on which the door 188 is positioned. A hinge crease 206 may be created on the door between the doubled over portion 198 and the inwardly extending sloping portion 200 to create a substantially flexible joint extending the height of the door 188 on the hinge side and allowing the door to flexibly pivot and, thus, open and close.

The wall panel with the door 188 may include a door opening over which the door is positioned and the perimeter edge of the door opening may be reinforced with an inwardly extending flange 208, a return portion 210 and an attachment flap 212. A handle or closure device 214 may be positioned on the inside of the door 188. The handle 214 may be positioned on the reinforced portion of the door 188 and may be configured for frictionally engaging the flange 208 of the reinforced perimeter of the opening when the door 188 is closed. A handle 214 may also be provided on the outside of the door 188 or the door 188 may be sized such that it falls short of the top of the wall opening near the top, such that the top edge of the door can be grasped and pulled open as shown in FIG. 1.

Turning now to FIGS. 15-24, the assembly of a pod 100 may be described. As shown in FIG. 15, four panels similar to those shown in FIGS. 6 and 7 may be arranged to cause their respective left 120 and right wall 126 edges to interlockingly engage such that the knuckles 134 on each edge are in alignment. Connecting pins or shafts 136 may be inserted into the aligned set of knuckles 134 thereby securing the adjacent panels together while also aligning the edges. In FIG. 15, a pair of connecting pins 136 are initially inserted but not fully driven into position. In FIG. 16, these connecting pins 136 are fully inserted. In FIG. 17, the first of four roof panels is being put into position. As shown, a first roof panel may be folded along the fold line relative to its respective wall panel. The roof panel's gable edge 166 may be interlockingly engaged with an adjacent panel's top/right gable edge 124 and the knuckles 134 on each edge may be aligned with one another. As shown in FIG. 18, a connecting pin or shaft 136 may be inserted through the series of aligned knuckles 134. FIG. 19 shows the fully inserted connecting pin 136. The remaining roof panels may be folded into place and secured with connecting pins 136. Referring to FIG. 20, the last roof panel may be folded into position. However, it is to be appreciated that folding the last roof panel into position may cause the series of aligned knuckles 134 to be concealed below the first roof panel that was folded into position. For this reason, a u-shaped slot 216 shown in FIG. 21 may be provided to allow for insertion of the last connecting pin or shaft 136. As shown in FIG. 22, the connecting pin or shaft 136 may be inserted and driven into position. FIG. 24 shows gluing of reinforcing tabs across the ridge edges.

FIGS. 28 and 29 shown alternative options for connecting pins or shafts 136. In one embodiment, pallet corner elements may be used. In another embodiment, a folded and glued corrugated tube may be provided. Still other shapes and types of connecting pins or shafts 136 may be provided. As shown, the shape of the knuckle may be adjusted for particular shapes of connecting pins or shafts to provide for a friction fit of the respective shaft 136. In the embodiments shown, the knuckle geometry is triangular, for example.

FIGS. 30-33 show several different potential geometries for the pod including a twelve sided pod with six panels, a six sided pod with six panels, a five sided pod with five panels and an eight sided pod with four panels having an igloo shape.

FIGS. 34 and 35 show alternative options for connecting the vertical and gabled edges of the pod. That is, rather than using interlocking aligned knuckles, a Velcro or other hook and loop joint could be used between abutting flanges or tape may be used to bridge the seams. In still other embodiments, a stapled approach may be used as shown in FIGS. 36 and 37. It is to be appreciated that the alignment provided by the knuckles with the connecting pin inserted therethrough may provide for relatively well aligned edges.

FIGS. 38 and 39 show additional options for a pod having six or four sides and having a dome roof.

FIGS. 40-43 show panel blanks that may be used to create the four panels of the pod. As shown, one embodiment may include geometrically similar two-faced panels that may be differentiated by the openings cut into the centers of the large panel faces (door, large circle, shapes) (see FIG. 6) or the small tube access cut out that allows for assembly (see FIG. 6).

In this embodiment, each panel may be stamped from a sheet of corrugated cardboard, such that the edges of the panels may be folded and fastened in place, forming the “knuckles” for the “piano hinges,” stiffening flanges, gabled edges, gabled corners, edges for cutout shapes and other pre-assembly design details. FIGS. 40-43 show the flat, stamped shape of each of the four pentagonal panels of one embodiment.

According to one embodiment, as shown in FIGS. 40-43, the pod 100 may be constructed by folding and assembling four similar cutout panels. Each panel may, in its flat unfolded condition include two major faces 218, 220. The largest of the two major faces 218 may be a generally pentagonal shape. The smaller of the two major faces 220 may also be a generally pentagonal shape, and this smaller face 220 may be attached to one of the five sides of the larger face 218, with a creased or fold line 154 in between the two faces 218, 220 to allow for folding and/or bending. When the four panels of this embodiment are assembled, the larger pentagonal face 218 of each of the panels may become an outer wall of the pod 100, and the smaller pentagonal face 220 of each of the panels may form part of the roof.

One of the panels may now be described in detail and while the flat blank of the panel is being described, the several edges of the panel may be referenced based on their purpose and or position in the constructed pod. For example a floor edge may reflect it is an edge at or near the floor of the pod 100 when the pod is constructed and a roof edge may reflect that it is an edge at or near the roof. Still other similar naming conventions may be used.

As shown in FIG. 40, for example, an inside face of a panel is shown. The larger of the two major faces 218 may include two roof edges 222, 224 that are substantially the same length and shorter than the other three edges; two wall edges 224, 226 that are substantially the same length, longer than the shorter edges, and that lie parallel to one another; and a fifth floor edge 228 that is longer than the other four edges. Other relationships of length may also be provided. The two roof edges 222, 224 may generally form the top edge of the wall formed by the larger major face 218 and each roof edge 222, 224 may extend across the top of the pentagonal face at an angle ranging from approximately 15 degrees to approximately 45 degrees or from approximately 20 degrees to approximately 40 degrees or from approximately 25 degrees to approximately 35 degrees. The two roof edges 222, 224 may, thus, slope upward from the wall edges 226, 228 toward the center of the panel and a peak when the two roof edges meet. The two wall edges 226, 228 may generally form the side edges where adjoining walls may be coupled to the larger major face 218. The floor edge 230 may, thus, extend between the two wall edges 226, 228 and may be generally perpendicular to the wall edges 226, 228 for forming the bottom edge of the wall panel near the floor of the pod when the pod is assembled. Various formations may extend from each of the five edges of the larger major face 218. On one of the shorter roof edges (i.e., edge 222) of the larger pentagonal face 218, the smaller pentagonal face may extend, with a fold line 154 along the border between the two pentagonal faces 218, 220. The smaller pentagonal face 220 may be described in more detail below.

On the other shorter roof edge (i.e., edge 224), two generally rectangular structures 232 may extend outward from the major face 218 to a free end. The long edges of the rectangular shapes may be parallel to each other and generally perpendicular to the roof edge 224. The rectangles may be substantially the same length and width and may be spaced from one another by a distance substantially equal to the width of the rectangular structures. At the free ends of the two rectangles, a third rectangular shape 234 may be arranged extending across the ends of the two rectangles with its long edges perpendicular to the first two rectangles and parallel to the roof edge 222. One short edge of the third rectangle may be flush with one long edge of the first rectangle. The opposite short edge of the third rectangle may extend beyond the second rectangle, and it may cut in toward the center of the third rectangle at an angle forming a V-shaped and notched end 236. At the base of one of the rectangles that is attached to the large pentagonal face, a trapezoidal shape 238 may be positioned and attached to a portion of the roof edge 222 of the pentagon and to the long edge of the rectangle 232. That is, the rectangle 232 may be inset from the end of the roof edge 222 and the trapezoid 238 may be positioned along the portion of the roof edge 222 that the rectangle 232 is inset from. Two of the sides of the trapezoid may be formed by the respective roof edge and rectangle and the remaining three edges may be free edges as shown.

When the panels are folded, the two rectangles 232 along the roof edge 222 of the pentagonal face 218 may each be folded three times as shown by the fold lines. The three folds may dissect the first and second rectangles along their long edges into four equal segments. Each of the folds dissecting the first and second triangles may be directed toward the large pentagonal face 218. Another fold, directed away from the large pentagonal face, may be made along the long edge of the third rectangle that joins the first and second rectangles. The third rectangle may be folded once along its length. The fold may begin at the point of the angle of the cutout at one short edge of the third rectangle, and may be folded in a direction away from the large pentagonal face. When the first and second rectangles are each folded into four equal segments, those four segments may form two “knuckles” of one half of a piano hinge that will allow for connecting to another panel of the roof of the complete pod. Part of the third rectangle may then be attached to the large pentagonal shape to hold the shape of the “knuckles.” Where the fold is made along the length of the third rectangle, the remaining portion of the third rectangle that is not attached to the pentagonal face may be attached to the two “knuckles” formed by the first and second rectangles, thus adding stability to the “knuckles.” A cross-section of the described folds may be seen with reference to FIG. 9, for example.

The wall edges of the larger pentagonal face may align parallel to one another at opposite sides of the pentagonal shape. From one of these parallel edges may extend two rectangles 240, with their long edges parallel to one another and parallel to the floor edge 230 of the pentagonal face. The two rectangles may be the same length and width, extend outwardly from the wall edge 228 to a free end, and have their respective long edges substantially parallel to one another and substantially perpendicular to the wall edges. At the free end of the rectangles, a third rectangular shape 242 may extend generally across the free ends of the two rectangles 240, with its long edges perpendicular to the first two rectangles 240 and parallel to the wall edge 228 of the pentagonal shape. One short edge of the third rectangle may be flush with one long edge of the first rectangle. The opposite short edge of the third rectangle may extend beyond the second rectangle, and it may cut in toward the center of the third rectangle at an angle forming a V-shaped notch 244 in the end of the third rectangle. Extending beyond the long edge of the third rectangle, furthest from the pentagonal face, may be a fourth and fifth rectangle. The fourth and fifth rectangles may be the same width as the first and second rectangles, and align along the same plane as the first and second rectangles. However, the fourth and fifth rectangles 246, 248 may be shorter than they are wide. Thus, one long edge of the fourth and fifth rectangles 246, 248 may lie along the long edge of the third rectangle. A tab-forming notch may be provided near the base of the fourth and fifth rectangles creating a tab for engaging the pentagonal panel when folded. The two rectangles may be spaced from one another forming a gap between them.

When the panels are folded, the first and second rectangles 240 along one of the wall edges of the pentagonal face may each be folded three times. The three folds may dissect the first and second rectangles 240 along their long edges into four equal segments. Each of the folds dissecting the first and second triangles may be directed toward the large pentagonal face. Another fold, directed away from the large pentagonal face, may be made along the long edge of the third rectangle that joins the first and second rectangles. The third rectangle may be folded once along its length. The fold may begin at the point of the angle of the cutout at one short edge of the third rectangle, and may be folded in a direction away from the large pentagonal face. When the first and second rectangles 240 are each folded into four equal segments, those four segments may form two “knuckles” of one half of a piano hinge that will connect the walls of the complete pod. Part of the third rectangle 242 may then be attached to the large pentagonal shape to hold the shape of the “knuckles.” Where the fold is made along the length of the third rectangle 242, the remaining portion of the third rectangle that is not attached to the pentagonal face may be attached to the two “knuckles” formed by the first and second rectangles, thus adding stability to the “knuckles.” Finally, a fold may be made along the long edge of the fourth and fifth rectangles 246, 248 that connects to the third rectangle. Upon assembly of the pod, the fourth and fifth rectangles 246, 248 may be attached to the “knuckles” of a second panel that joins at this hinge location. A cross-section of the folded shaped may be found, for example, in FIG. 10.

The second edge of the large pentagonal face that is parallel and of the same length as the edge just described may have similar extensions. The same structure consisting of five rectangles may be located along this edge of the large pentagonal face, but rotated 180 degrees. In addition, the V-shaped notch in the extended end of the third rectangle may be omitted.

The floor edge 230 may include a generally trapezoidal shape 250 extending outwardly therefrom. The trapezoidal edge may be folded to create a stiffened floor edge with a triangular cross-section as shown in FIG. 8. The trapezoidal shape may be provided to accommodate other panels being placed adjacent to the present panel and create a mitered corner of the cross-sectional shape of FIG. 8.

The smaller 220 of the two major panels, as mentioned, may extend from one of the roof edges of the larger major panel. This smaller panel 220 may be folded to form a portion of the roof as shown in FIGS. 1-4. This smaller panel may be substantially pentagonal having a first attached gable edge aligned with and matching the roof edge of the larger panel. This attached gable edge may define the fold line 154 between the larger major panel and the present smaller major panel. The smaller major panel may also have a free gable edge 252 extending generally outwardly from the attached gable edge at a selected angle such that when the smaller major panel is folded downward about the attached gable edge, the free gable edge 252 will join with the gable edge of a wall of an adjacent panel having a similar major pentagonal panel. The angle at which the free gable edge 252 extends may be selected taking into consideration the roof pitch defined by the major pentagonal panels and the number of panels being used in the pod. The free gable edge 252 may extend from the major panel outwardly to a free end. At the free end of the free gable edge, a far ridge edge 254 may extend substantially laterally from the free gable edge 252. The far ridge edge 254 may extend at an angle selected to allow the far ridge edge 254 to align with a near ridge edge, described below, of an adjacent panel. The far ridge edge 254 may be relatively short such that the opening in the top of the pod may be accommodated. The far ridge edge 254 may, thus, extend a short distance away from the free gable edge 252 to a roof opening edge 256. The roof opening edge 256 may extend away from the far ridge edge 254 slightly back toward the major panel and at an angle to the far ridge edge 254 such that a substantially square roof opening may be provided as shown in FIG. 4. The roof opening edge 256 may be relatively long compared to the far ridge edge 254 and may extend back toward the attached gable edge leaving a short distance. A near ridge edge 258 may extend from the roof opening edge 256 back to the attached gable edge closing the pentagon shape of the smaller major panel 220. The near ridge edge 258 may return to the attached gable edge at an angle selected to allow the near ridge edge 258 to align with a far ridge edge 254 of an adjacent panel when the panels are folded and the pod is assembled. Like the free gable edge 252, this angle may depend on the roof pitch selected and the number of panels used in the pod 100.

As shown, the free gable edge 252 may include a formation extending outward therefrom similar to the formation extending from the roof edge of the major pentagonal panel. That is, a pair of rectangular elements 260 may extend outward with a third rectangular element 262 extending across the ends. This formation may be folded to form a piano hinge with knuckles as shown in FIG. 9, for example. Each of the far and near ridge edges 254, 258 may include a substantially rectangular formation adapted for forming a joint as shown in FIG. 11. The roof opening edge 256 may include an inner rectangular formation and a trapezoidal formation adapted to form a stiffened free edge as shown in FIG. 12 and accommodate the intersection of the several edges of the opening at a mitered corner.

It is to be appreciated that the panels of FIGS. 40-43 may be substantially the same and for purposes of clarity, the numbering on FIGS. 41-43 has been omitted, but the same or similar elements are presumed to have a same or similar reference number. Four of the described panel assemblies may be folded as shown in FIG. 40. Each of the folded assemblies may be secured to adjacent assemblies using pins 136 in the form of paper tubes, for example, extending through the knuckle connections fainted by the folded edges of the panels.

It is also to be appreciated that the indicia on the patterns refers to folding up or down by a particular number of degrees. As such, FIGS. 40-43 show how to fold a particular panel into a wall/roof portion of the pod. Similarly, as shown in FIGS. 44-47, fold patterns are shown for other aspects of the pod including the door, the handle, the corner trim, and the inside gable patch, respectively.

The pod toy product may be designed for, but not limited to, children 2-6 years of age. The pod may be constructed primarily of corrugated cardboard and may be decorated with various craft materials including crayons, paints, markers and various glued on adornments. Additionally the pod may be used as an open-ended prop for a variety of pretend play activities.

The basic configuration, as shown, may include an enclosure with three child accessible openings. A door on one side, a circular opening on a second side, and a square opening in the top may be used by a child to enter or exit the enclosed space. Other polygonal shapes may be used in alternate designs for access openings. There may also be smaller openings that allow smaller objects to be put into or ejected from the enclosure. (FIGS. 1., 2., 3. & 4.)

At least some of the unique construction features of the pod are intended to meet two goals not found in corrugated children's products on the market today: abstract open-ended creativity and exceptional product strength and longevity. First, the abstract geometric design of the pod is intended to evoke the imaginations of children to define the toy in a way that is personal. The creative process of decorating and the creative imaginative play functions are both open-ended and determined by the children decorating and playing with the toy. Second, the pod is designed to hold up to normal wear and tear and mild abuse and last for as long as the toy is engaging to the child. The strength and durability of the toy is intended to be more comparable to plastic toys on the market than existing corrugated toys designed to last weeks.

The method of product assembly allows the pod product to be packaged efficiently while reducing or minimizing shipping costs. The use of paper tubes in the assembly simplifies the assembly process and maximizes structural integrity to the finished product.

Though future research may accommodate alternate materials for these products, corrugated cardboard and paper tube were chosen to satisfy the two main goals of creativity and sustainability. The product may also be constructed of corrugated plastic sheet, foam-core, wood, metal, structural foam molded plastic, injection molded plastics or rotationally molded plastics. Each material may cause alterations in some details of the design, but the same or similar form and function may remain. The product may also be constructed of a metal frame (e.g., extruded or formed aluminum) and corrugated, wood or plastic panels.

Using corrugated cardboard provides a high level of creative flexibility as virtually any arts and crafts material may be used in the decorating process. The relatively light weight of the material allows children to move and rotate the toy at will in their self-driven creative play adventures. Corrugated cardboard and paper tubes may be made using local natural resources and containing relatively high amounts of recycled materials. The end product and packaging are also recyclable and biodegradable.

The geometry of the pod may include four vertical pentagonal side surfaces and four angled pentagonal top surfaces. Other configurations were considered and may be used in other permutations of the product. Examples of alternate configurations are shown in attached illustrations (FIGS. 30., 31., 32. & 33.) Some considerations for the geometry of the original design include aesthetics, function, safety, structural integrity and ease of assembly.

The product may be made from four geometrically identical, or substantially identical, two-faced panels that are differentiated only by the openings cut into the centers of the large panel faces (door, large circle, shapes) (see FIG. 6). The remaining panel with no such surface openings is differentiated by a small tube access cut out that allows for proper assembly (see FIG. 6). It is to be appreciated that the small tube access cutout may be positioned in any of the panels and may affect the order in which the panels are assembled.

Alternative designs may implement three, four, five, six or eight geometrically identical panels designed as one, two or three-faced panels (e.g. FIGS. 30., 31., 32., 33.). In these examples, alternate panel attachment methods may be used as well as different panel configurations.

The remaining pieces (i.e., in addition to the four two-faced panels) may include two sets of four paper tubes (1″ ID×0.100″ wall thickness). One set of tubes may measure 15.5″ in length and the second set may measure 12″ in length. The tubes may be used to hold the four panels together. The tubes may be different diameters, lengths and wall thicknesses depending on the design. In the present case, the longer tubes are used for the wall joinery and the shorter tubes are used for the gable joinery.

Several design details of the pod are advantageous to building a toy that will last a reasonable lifespan, while maintaining safety and optimizing function, aesthetics and value. Several alternative designs were researched and some tested prior to the design depicted in the figures.

The corner attachment on the vertical and gable corners implement a “piano hinge” style of alternating corrugated sheet (44 ECT 3/16″ thick) wrap arounds, or square tube “knuckles” held together by a paper tube (1′ ID×0.100 wall thickness) (FIGS. 9. & 10.). Alternate designs included fabricating the corrugated tube “knuckles” into hexagonal or octagonal shapes to fit various tube sizes. Alternate designs for the tube were also considered including standard pallet corners and corrugated sheet formed into triangular or square tubes (see FIGS. 28 & 29). Future product designs may implement these alternatives. Alternate “non-piano hinge” joint designs were also considered including a “Velcro Butt Joint Corner” (FIG. 34.), “Tape Butt Joint Corner” (FIG. 35.) and “Trim Staple Butt Joint Corner” (FIGS. 36. & 37).

The design depicted and many of the alternate designs include buttresses folded back around to support the wraparound corrugated polygonal (square, parallelogram, octagon, triangle) tubes. These buttresses act to position and shape the tube, add strength to the overall structure and provide a cleaner interior aesthetic.

Exposed edges and the abutted gabled edges of the panels may be strengthened and stiffened by forming and gluing in place a triangular (cross sectional) tube or gusseted stiffening flange. These reinforcing stiffening flanges are mitered or trimmed to mate up with adjoining panels. (See FIG. 8., FIG. 11. & FIG. 12). The mitered corners of the base flanges also act to contain the paper tubes used to connect the panels and create a smooth clean bottom surface. (FIG. 5)

The pyramidal geometry of the top or roof of the Curio Pod adds to the structural integrity of the assembly and avoids an elevated horizontal surface that would be less safe. For example, broad horizontal surfaces may become a convenient place to set breakable objects or entice children that are too small to climb onto them. The resulting corners of the pyramidal shape are obtuse (less sharp) and are therefore less likely to cause accidental minor injuries. Alternative roof designs include a domed roof (FIGS. 38. & 39) for any polygonal construction (square, pentagonal, hexagonal, etc.) as well as the designs already shown (FIGS. 30-33).

The top seams of the pod may be secured and sealed by outer trim pieces and inside gluing flaps made from thinner “E Flute” ( 1/16″ thick) corrugated cardboard. These gluing tabs may be glued together by the customer in the final steps of the assembly process. Other materials and designs for the trim and gluing flaps were tested and may be used in the future. The four inside gluing flaps (FIG. 23) may be glued first to hold the four top seams together. The interlocking outer trim tabs (FIG. 24 & FIG. 25) may be glued to further secure the top seams completing the assembly of the pod. Alternate methods could also be used to seal these seams including: Velcro or other hook and loop products, pressure sensitive adhesive (PSA) (FIG. 34), paper tape (FIG. 35) or staples (FIGS. 36 & 37).

Details of the Curio Pod door design may provide strength, safety and ease of operation (FIG. 1, FIG. 44, FIG. 26 & FIG. 27). Folding over the corrugated material and gluing creates a double thick door hinge flap, which is glued to the reinforced framed opening of the pod (FIG. 14-A & FIG. 14-B). Around the inside perimeter of the door, a beveled frame may be provided to provide stiffness and strength while eliminating potential finger pinch points. The outer end corners of the door may be rounded for safety. The ¾″ gap at the top of the door may function as an outer handle for opening as well as a mail slot or peek out (FIG. 26 & FIG. 27). An alternate hinge method may be used employing the “piano hinge” method of alternating corrugated sheet wrap arounds, or square tube “knuckles” held together by a paper tube. Similar to the design used to attach the corners of the Curio Pod. The size of the “knuckles” and paper tube diameter may be smaller in the hinge design than in the corner attachments.

The Handle/Closure employs an interference fit between the panel opening frame and the protruding handle legs (FIG. 13-A & FIG. 13-B). The shape of the handle mounted to the 45° beveled frame surface allows the curved sides of the handle to slide into the side of the panel frame with enough friction to keep the door closed. The friction fit may then easily be overcome by a child to open the door. The handle may be folded over and glued to be double thick to increase strength and improve function (FIG. 45).

The pod was designed to be packed into an economical shipping package while allowing for easy assembly by the customer resulting in a product with superior structural integrity. The four similar folding panels may be held together using sturdy paper tubes (1″ ID×0.100″ wall) to join both the four vertical corners and the top gable corners. The tubes may allow for easy assembly while adding strength to the overall structure (FIG. 6 & FIG. 7). The four vertical tubes (FIG. 15 & FIG. 16) are contained when the four top panels are attached using the shorter paper tubes (FIGS. 17, 18, 19 & 20). The final tube may be installed in the top by folding back a “U” shaped tab in the corner of one of the top panels (FIG. 21 & FIG. 22). This opening may then be covered and sealed in the final gluing assembly. The final steps of gluing the inside flaps and outer trim tabs solidifies the structure and creates a safe toy free of accessible gaps (FIG. 23 & FIG. 24).

The corrugated cardboard pieces of the pod may be stamped out using the latest corrugated die-cutting manufacturing processes. The pieces may then be folded and glued into shape by hand with the aid of assembly fixtures. Design details including: relief radii, rounded corners, clearances, locator flanges, mitered corners and perforated back-folds may be implemented to ease assembly and improve durability, safety and strength. The cut out patterns of the four panels may include inside radii for all of the openings to relieve stress on the folded corners and resist tearing (FIG. 41.-43.). These include the four rectangular openings and three partial rectangular cut-outs that form the wrap around knuckles on the edges of all four panels. The door opening, large circle opening and small shapes openings implement inside cut radii between the flaps also. Two small flanges on both sides of each panel may serve to position the vertical wrap around knuckles in the manufacture assembly process. These four tabs implement radius notches and a perforated crease to prevent tearing on the back fold.

Various embodiments of the present disclosure may be described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products. It is understood that each block of the flowchart illustrations and/or block diagrams, and/or combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer-executable program code portions. These computer-executable program code portions may be provided to a processor of a general purpose computer, special purpose computer, or other programmable data processing apparatus to produce a particular machine, such that the code portions, which execute via the processor of the computer or other programmable data processing apparatus, create mechanisms for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. Alternatively, computer program implemented steps or acts may be combined with operator or human implemented steps or acts in order to carry out an embodiment of the invention.

Additionally, although a flowchart may illustrate a method as a sequential process, many of the operations in the flowcharts illustrated herein can be performed in parallel or concurrently. In addition, the order of the method steps illustrated in a flowchart may be rearranged for some embodiments. Similarly, a method illustrated in a flow chart could have additional steps not included therein or fewer steps than those shown. A method step may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc.

As used herein, the terms “substantially” or “generally” refer to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” or “generally” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking, the nearness of completion will be so as to have generally the same overall result as if absolute and total completion were obtained. The use of “substantially” or “generally” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, an element, combination, embodiment, or composition that is “substantially free of” or “generally free of” an ingredient or element may still actually contain such item as long as there is generally no measurable effect thereof.

In the foregoing description various embodiments of the present disclosure have been presented for the purpose of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The various embodiments were chosen and described to provide the best illustration of the principals of the disclosure and their practical application, and to enable one of ordinary skill in the art to utilize the various embodiments with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the present disclosure as determined by the appended claims when interpreted in accordance with the breadth they are fairly, legally, and equitably entitled. 

What is claimed is:
 1. A pod toy comprising: a plurality of substantially similar panels each having a wall portion and a roof portion, the plurality of panels having at least one interlocking edge having alternating notches and knuckles configured for engaging adjacent panels, wherein, when assembled, the interlocking edge of a first panel engages an interlocking edge of a second panel by aligning knuckles of the first panel with knuckles of the second panel; and a connecting pin configured for insertion into and through the knuckles at the interlocking edges.
 2. The pod toy of claim 1, wherein each panel of the plurality of substantially similar panels is foldable from a single piece of material.
 3. The pod toy of claim 2, wherein the single piece of material is substantially flat with no overlapping portions.
 4. The pod toy of claim 1, wherein the plurality of substantially similar panels differ due to surface openings and are substantially identical along their respective interconnecting edges.
 5. The pod toy of claim 1, wherein the wall portions of the plurality of substantially similar panels form four walls.
 6. The pod toy of claim 5, wherein the wall portions include a gable shape.
 7. The pod toy of claim 5, further comprising a pyramidal shaped roof.
 8. The pod toy of claim 7, wherein the pyramidal shaped roof is rotated 45 degrees from the orientation of the four walls.
 9. The pod toy of claim 7, further comprising a roof opening in the center of the roof.
 10. The pod toy of claim 1, wherein the plurality of substantially similar panels comprise a sustainable material.
 11. The pod toy of claim 10, wherein the sustainable material is cardboard.
 12. The pod toy of claim 11, wherein the connecting pin is a paper tube.
 13. The pod toy of claim 1, wherein the plurality of substantially similar panels each define a wall having a bottom free edge, a left interlocking edge, a right interlocking edge, an interlocking gable edge, and a folded gable edge.
 14. The pod toy of claim 13, wherein the left interlocking edge is configured to interlock with an adjoining right edge of an adjacent panel.
 15. The pod toy of claim 14, wherein one of the substantially similar panels includes a door opening and a door.
 16. The pod toy of claim 15, wherein the door comprises an interior handle configured for frictionally engaging a door jamb of the door opening.
 17. The pod toy of claim 16, wherein one of the plurality of substantially similar panels includes a slot in a roof portion for insertion of a connecting pin therethrough.
 18. The pod toy of claim 1, wherein the knuckles have a substantially square cross-section.
 19. The pod toy of claim 1, wherein the knuckles have a substantially parallelogram shaped cross section.
 20. The pod toy of claim 1, wherein the roof portion can support a child weighing 75 pounds. 